Cold wax process for forming candles

ABSTRACT

A process for molding wax candles at room temperature. The wax is first reduced to particles and then compressed into a product at a pressure and mold closing time capable of developing a sufficient internal heat from the heat of compression and the heat of friction to fuse the wax into a solid, substantially uniform density product. Necessary to the invention the particles employed in the process must be reduced to a size or shape capable of producing the necessary heat of compression and heat of friction for fusing the wax substantially uniformly throughout the product. The apparatus employed includes pressure operated plungers which are arranged to move mold members at a speed and at a force such that the heat of compression and heat of friction developed in the crystalline structure of the wax reach a temperature capable of fusing the wax without the application of outside heat. The apparatus also includes wick feeding mechanism capable of holding wicks under tension in a cavity when the candles are being molded.

United States Patent Kelley 151 3,689,616 1451 Sept. 5, 1972 [54] COLDWAX PROCESS FOR FORMING CANDLES 72] Inventor: Bernard B. Kelley,Sherwood, Oreg. [73] Assignees: Joseph Vergeer, 4, Portland, 0reg.;

Barfred ..264/ 144 Primary ExqminerRobert F. White Assistant Examiner.l.R. Hall Attorney-Eugene M. Eckelman [57] ABSTRACT A process for moldingwax candles at room temperature. The wax is first reduced to particlesand'then Y compressed into a product at a pressure and mold closing timecapable of developing a sufficient internal heat from the heat ofcompression and the heat of friction to fuse the wax into a solid,substantially uniform density product. Necessary to the invention theparticles employed in the process must be reduced to a size or shapecapable of producing the necessary heat of compression and heat offriction for fusing the wax substantially uniformly throughout theproduct. The apparatus employed includes pressure operated plungerswhich are arranged to move mold members at a speed and at a force suchthat the heat of compression and heat of friction developed in thecrystal-.

line structure of the wax reach a temperature capable of fusing the waxwithout the application of outside heat. The apparatus also includeswick feeding mechanism capable of holding wicks under tension in acavity when the candles are being molded.

9 Claims, 7 Drawing Figures PATENTEDSEP 1912 I 3.689.616

-- I as C; \Y O FIG. 6 53 l.

v ATTY BACKGROUND OF THE INVENTION This invention relates to a novelprocess for molding products from wax and more particularly is concernedwith a cold wax formulation of products. The invention is illustratedherein as being associated with the making of candles, but it is to beunderstood that any type of wax product capable of being molded can bemade by the present process.

Candles have heretofore been made in various ways. For example, circularcandles are usually formed by multiple dippings in a vat of molten wax.As another example, molten wax is poured into molds, and when the waxhas solidified the mold is opened. Such prior processes have distinctdisadvantages, a common one of which is that fast production cannot beattained without a vast array of machinery. That is, in the process offorming the candles by dipping, the multiple dipping requiresconsiderable time, and in the process where the candles are molded bypouring molten wax into a form, cooling time for the wax in the moldslows the process considerably. This latter process also has thedisadvantage that the wax shrinks as it solidifies and a pocket forms inthe top surface of the candle to detract from the appearance, or, inmost instances, the mold is filled with the bottom side up andsubsequent pours to the initial one are made until all shrinkage isfinally compensated for.

SUMMARY OF THE INVENTION According to the present invention and forminga primary objective thereof, a process is provided for the cold moldingof wax into products having a substantially uniform density.

More particularly, an object of the present invention is to provide aprocess of cold molding of wax products including the step of reducingsolid wax to a particle size which is capable of producing a heat ofcompression and heat of friction sufficient to fuse the particlestogether when subjected to selected mold pressures and mold closingtimes.

The invention will be better understood and additional objects andadvantages will become apparent from the following description taken inconnection with the accompanying drawings which illustrate a preferredform of the device.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an end elevational view,somewhat diagrammatic, of apparatus for forming particles capable ofbeing used in the present process;

FIG. 2 is an enlarged fragmentary elevational view of particle cuttingmeans of the apparatus of FIG. 1, such view being taken on the line 2-2of FIG. 1;

FIG. 3 is an enlarged fragmentary sectional view taken on the line 33 ofFIG. 2;

FIG. 4 is a perspective view of a particle capable of use in the presentprocess and, such particle being produced by the cutting apparatus ofFIGS. 1-3;

FIG. 5 is a detail view, greatly enlarged, of a wax crystal;

FIG. 6 is a top plan view of a molding machine for carrying out theprocess of the present invention; and

FIG. 7 is an enlarged fragmentary sectional view taken on the line 77 ofFIG. 6.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT According to the invention,wax is capable of being molded into a product having substantiallyuniform density throughout without first being reduced to a moltenstate. Briefly stated, the invention comprises first reducing solidifiedwax to particles which are of a size or shape which makes them capableof being fused together into a product by internal heat created by heatof compression and heat of frictionQThe type of wax used may be any typewhich can be fused in the manner just stated and of course any typewhich is capable of serving as a selected product such as a candle. Asis well known, a paraffin type wax is mostly used for candleconstruction, and with reference to FIG. 5, a crystal 10 of such waxcomprises a plurality of stick-like fragments 12 disposed in haphazardarrangement. It has been found that in the compressing of wax crystals,the fragments 12 being re-arranged and compressed together develop heat,and upon being pressure molded at selected pressures and at selectedclosing speeds, sufficient heat is developed to fuse the crystals into asolid mass of substantially uniform density.

Accordingto the invention, in order for the molding step to develop thenecessary heat of compression and heat of friction to fuse the wax intoa product having a substantially uniform density throughout, the waxfirst must be reduced to a selected particle size or shape. That is, itis necessary as one example that the wax be reduced to thin flakes orshavings 14. The surface size of the flake is not particularlyimportant, the important feature being that it have one dimension thatis small so that the crystals are subjected to maximum rearrangement andfrictional engagement when compressed.

FIGS. 1, 2 and 3 show apparatus for producing the flakes 14. Suchapparatus comprises a drum-like structure 16 having a peripheral surface18. The drum 16 is mounted on a shaft 20 adapted to be driven by powermeans, not shown. Drum surface 18 has a plurality of cutting teeth 22formed therein, such teeth, as best shown in FIGS. 2 and 3, beingimpressed outwardly as a part of and from the surface 18 of the drum. Anopening 24 is provided forwardly of the teeth with relation to thedirection of rotation of the drum, such direction being designated bythe arrow 26 in FIG. 3. Upon rotation of the drum, a bar of wax 28 ismoved through a guide 30 for contact with the surface of the drum 16.The drum cuts off particles of wax in substantially the shape of theshavings shown in FIG. 4, and the openings 24 allow the wax shavings tobe directed interiorly of the drum. The drum may be tilted axially todischarge the shavings 14.

The shape of shavings 14 shown in FIG. 4, comprises only an exemplaryshape of particles which may be employed in the process of the presentinvention, and similarly the wax cutting apparatus of FIGS. 1, 2 and 3is only exemplary of apparatus which may be employed for producingparticles. Thus it is to be understood that the present invention,wherein wax particles can be fused into a solidified product by the heatof compression and the heat of friction resulting from a compressingstep, may be carried out with other types of particles, such as flakes,wafers, wholeor factured pellets, and the like.

Mold apparatus for carrying out the method invention is illustrated inFIGS. 6 and 7. As seen in the plan view of FIG. 6, the mold comprises abase plate 32 having four upright posts 34 secured integrally thereto,as by cap screws 33. Secured on top of the posts 34, as by cap screws35, is a top plate 36 having a center aperture 37 adapted to be closedby a cover plate 38 removably secured to the plate 36, as by cap screws40. Bottom plate 32, insert 38 and the posts 34 form a mold cavity 42 incombination with mold inserts 44 secured on laterally movable plungerheads 46, as by screws 48. Plunger heads 46 are secured to piston rods50 extending from piston heads 52 operating in cylinders 53, such ashydraulic cylinders, in a well known manner. It is thus apparent thatthe plunger heads 46 and their respective inserts 44 can be moved'inwardly to compress wax, which was inserted when the cavity was openinto a product 54 such as a candle.

The cover plate 38 of the mold is provided with a circular dependingcentral projection 56 for providing a recess 57 in the candle into whicha short length of a wick 58 projects. Also, the inserts 42 on theplunger heads 46 may have suitable contours 60 for forming designs 61 onthe sides of the candles in the molding process. The face surfaces ofthe inserts 42 may either be recessed as shown in FIG. 7 to formprojections as the designs on the candles or if the design is tocomprise a recess in the candle the contours 60 may comprise projectionson said face surfaces.

For the purpose of preventing wax from adhering to defining parts of thecavity, such cavity parts are provided with lubricant coatings orcoverings which will not adhere to wax. For example, base 32 and thecover plate 38 have an inner coating of low friction coefficient teflonand the inserts 42 may be coated or constructed of similar material orheat treated polyurethane.

It is desired that wick feeding mechanism be employed in combinationwith the molding apparatus. For this purpose, a drum 64 having a wicksupply thereon is rotatably supported on brackets 66 depending from thebase plate 32 in integral relation. Base plate 32 has an aperture 68through which the wick 58 passes and cover plate 38 similarly has anaperture 70 for receiving the wick. A tension spring 72 is connectedbetween the drum 64 and the bottom plate 32 and is adapted for removableconnection with a plurality of holes 74 in the drum. Cover plate 38 hasa gripping device 76 for holding the free end of the wick. In theoperation of the device, the wick 58 is pulled upwardly manually and thefree end attached to the gripping device 76. Such is accomplished whenthe mold is open and against the action of spring 72 so that the wick isheld in tensioned relation as the mold is closed, thus providing astraight wick in the candle disposed on the axis of the candle. Spring72 is detachably engaged with a selective hole 74 in the drum 64 toaccomplish the desired tensioning action on the wick.

To form a candle, the mold is opened by withdrawing the heads 46 andopening the cover plate 38. The wick is drawn upwardly into place andpassed through the cover plate 38 for attachment to the gripping device76. The mold is charged with wax particles, and upon operation of theplunger, the candle is formed. The candle 54 is removed after openingthe mold and the wick cut off as desired.

According to the present process, candles are adapted to be formed at afast rate. That is, the candle is substantially completed when the moldis fully closed as opposed to molten processes which must wait for thewax to solidify. The mold is closed at a force and at a speed capable ofdeveloping sufficient heat from compression and friction to produce aninternal temperature in the wax to fuse the wax. The force used forclosing the mold as well as the closing speed will vary, depending uponthe grade or type of wax used. Where paraffin wax is used, as anexample, approximately 2,500 p.s.i. is a preferred mold pressure at aclosing speed of approximately 3 inches in 4% seconds. Certain grades ofparaffin waxes or even other classes of waxes may require a greater orlesser mold force and a faster or slower closing speed. Most types ofwaxes, however, for forming candles can be fused in a pressure range offrom 1,700 to 2,800 p.s.i. and at closing speeds in the range of from 3inches in 3% seconds to 3 inches in 4% seconds.

The force used and the closing speed may also depend upon the size andtype of particle 14. For example, if the particles 14 are rather smallor thinly cut, less force is required to develop the necessary heat tofuse the wax than if larger particles are used, it being apparent thatsuch a greater force is required for the larger particles since thecrystals in larger particles are more difficult to rearrange andcompress. A much more uniform density product is formed by the use ofsmall particles. A preferred particle size is one/sixteenth tothree/sixteenths inch in one dimension, such as the thickness, whetherflake construction or pellet construction, or otherwise.

The present process requires a dwell time of approximately sevenseconds, making it apparent that products can be formed very rapidly ascompared to molds of the type which must wait for molten wax tosolidify.

It has been found that according to the present process the density ofthe candle, while being substantially uniform throughout, is veryslightly greater in the area adjacent to the surfaces thereof than atthe middle, and such is important in that when the candle is lit it willburn down the middle and leave an outer shell, thus preventing wax fromflowing over the sides. The general surface texture of the candledepends upon the size of particles used in that the smaller the particlethe finer the texture and the larger the particles the coarser thetexture. Although the drawings illustrate the product as being square incross section, it is to be understood that it may be round or of othercontour.

It is to be understood that the form of my invention herein shown anddescribed is to be taken as a preferred example of the same and thatvarious changes in the shape, size or arrangement may .be resorted towithout departing from the spirit of my invention or the scope of thesubjoined claims.

Having thus described my invention, 1 claim:

1. The process of forming a candle from crystalline wax comprising:

a. reducing a solid mass of said wax into selected particles of a sizehaving one dimension so small that the crystals of the wax are subjectedto maximum rearrangement and frictional engagement when the waxparticles are compressed,

b. placing a charge of the wax particles into a mold containing a candlewick,

c. compressing the wax particles in the mold around the wick withpressing means moving at a speed and at a pressure sufficient that theheat of friction and the heat of compression between the wax particlesreaches a temperature to fuse the particles into a unitary mass, withoutoutside heat, within a dwell time of approximately 7 seconds,

d. cooling the unitary mass to a solidified state, and

e. removing from the mold, the resulting formed candle.

2. The process of claim 1 wherein said reduction of the wax intoparticles comprises cutting flake-like pieces from a body of solid wax.

3. The process of claim 1 wherein the speed of the compressing member isin the range of from 3 inches per 3% seconds to 3 inches per 4% seconds.

4. The process of claim 1 wherein the speed of the 8. The process ofclaim 1 wherein the compressing step is accomplished from at least twosides of the charge of wax.

9. The process of claim 1 wherein the compressing step is accomplishedfrom four sides of the charge of wax.

1. The process of forming a candle from crystalline wax comprising: a.reducing a solid mass of said wax into selected particles of a sizehaving one dimension so small that the crystals of the wax are subjectedto maximum rearrangement and frictional engagement when the waxparticles are compressed, b. placing a charge of the wax particles intoa mold containing a candle wick, c. compressing the wax particles in themold around the wick with pressing means moving at a speed and at apressure sufficient that the heat of friction and the heat ofcompression between the wax particles reaches a temperature to fuse theparticles into a unitary mass, without outside heat, within a dwell timeof approximately 7 seconds, d. cooling the unitary mass to a solidifiedstate, and e. removing from the mold, the resulting formed candle. 2.The process of claim 1 wherein said reduction of the wax into particlescomprises cutting flake-like pieces from a body of solid wax.
 3. Theprocess of claim 1 wherein the speed of the compressing member is in therange of from 3 inches per 3 1/2 seconds to 3 inches per 4 1/2 seconds.4. The process of claim 1 wherein the speed of the compressing member isapproximately 3 inches per 4 1/2 seconds.
 5. The process of claim 1wherein the compressing pressure is in the range of from 1,700 psi to2,800 psi.
 6. THe process of claim 1 wherein the compressing pressure isapproximately 2,500 psi.
 7. The process of claim 1 wherein thecompressing pressure is approximately 2,500 psi and the speed of thepressing member is approximately 3 inches per 4 1/2 seconds.
 8. Theprocess of claim 1 wherein the compressing step is accomplished from atleast two sides of the charge of wax.
 9. The process of claim 1 whereinthe compressing step is accomplished from four sides of the charge ofwax.